Possibly new broken stud removal technique!

[ChrisBennet]

I came across this while searching for something else http://www.urs4.com/technical/repair/stud/stud.html

It details a method for removing studs that are broken off below the surface without drilling. I'd never heard of this method and I thought it might be of interest.

In a nutshell this is the method:
"Using a welder, slowly build up a bead of weld on top of the stud, until it clears the surface of the head. Using vice grips, grab the weld and twist out the stud remains."
-Chris

[Doug Zielke]

Dilavar studs resist welding.

[RickM]

Cool stuff Chris.

What about weld on the threads? Whatis OXYMIG?

With some refinement this could be a pretty attractive technique.

[ChrisBennet]

Originally posted by Doug Zielke
Dilavar studs resist welding.

Good point. All the broken 911 head studs I've seen (<10), broke off above the surface so this technique wouldn't have been applicable those them anyway.

It wouldn't work for 911 exhaust studs either - unless you turned the motor upside down.

-Chris

[mwildt]

Hi,

Even if you can't weld onto dilavar studs I'm sure the current from the welder could be enough to get it going. I found this on the web too:

------------
Re: Successful broken exhaust stud removal[900/1992] posted by A. Gary DiFrancesco on
Monday, 27 November 2000, at 8:44 a.m.

Last spring I removed the head off my '87 745T due to a broken stud. In my case, the stud broke flush with the head, so there was no way to get a wrench on it. Took the head to a head shop and had the machinist replace all the studs, figuring that if one stud is bad, more were ready to let go.

The machinist trick to removing the remaining studs was amazingly simple and effective. He hooked up the hot side of his welder to the stud, the ground to the block. Set the welder for about 150 amps., then turned the welder on for 2 seconds. The studs after this treatment are hot to the touch, and the head is a bit warm. But the crud in the threads that makes the stud stick is all burned out. It is the crud that is causing the high electrical resistance. Hence, it is the crud that really heats up and burns off. With the curd burned off, he is able to easily unscrew the stud. He finds better than 90% of stuck studs can be removed this way. And there is not warping of the head since the heat is pretty much contained to the cruddy threads and is only applied briefly.

Just one of those welder tricks I have filed away for the day when I get a welder.

--
Gary DiFrancesco

-------------------

Michael

[ChrisBennet]

I know a machinist that does it that way only he uses a car battery.
-Chris

[thabaer]

I'll query Scott and Jeff, many S-heads also have 911s, one of them may have encountered dilivar.